Photovoltaic module assembly

ABSTRACT

A photovoltaic module assembly, comprising: a first layer; a back layer, wherein the back layer comprises a second layer, a third layer, and a support layer located between the second layer and the third layer; and a photovoltaic layer comprising photovoltaic cells, wherein the photovoltaic layer is located between the first layer and the back layer; wherein the support layer comprises a stiffening element.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/768,938 filed Feb. 25, 2013 and is acontinuation application of U.S. application Ser. No. 14/187,998 filedFeb. 24, 2014. The related applications are incorporated herein byreference.

TECHNICAL FIELD

Disclosed herein are photovoltaic (PV) module assemblies.

BACKGROUND OF THE INVENTION

A PV assembly usually comprises a front sheet, generally made from atransparent or semi-transparent material such as glass, a polymer, orlike materials. When the front sheet is a glass layer, a frame istypically required, which can generally be made of aluminum. The frameand the glass layer are the biggest contributors to the weight of the PVmodule assemblies, which can make the assemblies generally heavy andexpensive to produce. When a polymer is instead used as the collectormaterial, the mechanical properties and/or the optical efficiency of thePV assembly can be decreased. For example, for forming the collector,the polymer poly(methyl methacrylate) is good for light transmission(i.e., high optical efficiency), but lacks sufficient mechanicalproperties. Polycarbonate has good mechanical properties for producingthe flat sheet, but has a lower optical efficiency.

Accordingly, there is a need for PV module assemblies with one or moreof increased production rates, reduced assembly times, and decreasedweight, while maintaining the desired mechanical and/or electricalperformance properties.

SUMMARY OF THE INVENTION

Disclosed, in various embodiments, are photovoltaic modules, and methodsfor making and using the same.

In an embodiment, a photovoltaic module assembly, comprises: a firstlayer; a back layer, wherein the back layer comprises a second layer, athird layer, and a support layer located between the second layer andthe third layer; and a photovoltaic layer comprising photovoltaic cells,wherein the photovoltaic layer is located between the first layer andthe back layer; wherein the support layer comprises a stiffeningelement.

These and other features and characteristics are more particularlydescribed below.

DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings wherein likeelements are numbered alike and which are presented for the purposes ofillustrating the exemplary embodiments disclosed herein and not for thepurposes of limiting the same.

FIG. 1 is a cross-sectional side view of an embodiment of a PV moduleassembly.

FIG. 2 is a cross-sectional view of a support layer taken along line A-Aillustrating an example of a honeycomb array.

FIG. 3 is a cross-sectional view of a support layer taken along line A-Aillustrating an example of a triangular array.

FIG. 4 is a cross-sectional view of a support layer taken along line A-Aillustrating an example of an R6 array.

FIG. 5 is a cross-sectional view of a support layer taken along line A-Aillustrating an example of a hexakis array.

FIG. 6 is a schematic representation of Sample A of Example 1.

FIG. 7 is a schematic representation of Sample B of Example 1.

FIG. 8 is a schematic representation of Sample C of Example 1.

DETAILED DESCRIPTION OF THE INVENTION

PV module assemblies can generally comprise a frame, a junction box,cables, connectors, a ground fault circuit interrupter (GFCI), amounting system, a tracking system, a combiner box, a back layer,encapsulant layers (e.g., ethylene vinyl acetate encapsulant layers),wafers (i.e., PV cells), an anti-reflective layer, and/or a front layerof glass. The frame, when present, can generally be made of aluminum.The aluminum frame and the glass layer are the biggest contributors tothe weight of the PV module assemblies, which can make the assembliesgenerally heavy and expensive to produce. Glass accounts for the largestpart of the weight of a PV module assembly. When the glass is replacedwith a material such as plastic, the resulting PV module assemblyresults in a much lighter assembly (e.g., less than or equal to 10kilograms per square meter (kg/m²), specifically less than or equal to 5kg/m², for assemblies without glass as compared to 13 kg/m² forassemblies with glass), which can allow for placement on roofs havinglimited load bearing capacity (e.g., flat roofs). Replacing glass withplastic also generally results in a reduction in mechanical properties(e.g. stiffness and/or flexural strength) of the overall assembly. Itwas unexpectedly discovered that when a support layer is incorporatedinto the back layer, the mechanical properties of the PV module assemblycould be increased without significantly increasing its weight.

As disclosed herein, a PV module assembly (also referred to as a PVmodule or a PV assembly) can comprise one or more of a first layer, aphotovoltaic layer comprising a photovoltaic cell and a curedcomposition, a back layer comprising a second layer, a support layer,and a third layer, a junction box, cables, a micro-inverter, and anoptional connector connecting the first layer to the second layer.

A more complete understanding of the components, processes, andapparatuses disclosed herein can be obtained by reference to theaccompanying drawings. These figures (also referred to herein as “FIG.”)are merely schematic representations based on convenience and the easeof demonstrating the present disclosure, and are, therefore, notintended to indicate relative size and dimensions of the devices orcomponents thereof and/or to define or limit the scope of the exemplaryembodiments. Although specific terms are used in the followingdescription for the sake of clarity, these terms are intended to referonly to the particular structure of the embodiments selected forillustration in the drawings, and are not intended to define or limitthe scope of the disclosure. In the drawings and the followingdescription below, it is to be understood that like numeric designationsrefer to components of like function.

FIG. 1 illustrates a schematic view of the individual components of a PVmodule 10, wherein the PV module 10 can comprise a first layer 12; asecond layer 32 that comprises a cured composition and a PV cell 14; anda back layer 30 that comprises a second layer 32, a support layer 34,and a third layer 36. FIG. 1 also illustrates that the PV module 10 cancomprise a connector 20 and/or 22 (20,22) that can connect the firstlayer 12 and the second layer 32. The connector 20,22 can be formed(e.g., molded) as part of either the first layer 12 or the second layer32 or the connector 20,22 can be a separate piece, as illustrated inFIG. 1. The connector 20,22 can be welded (e.g. fusion welded or laserwelded) to the first layer 12 and/or the second layer 32. For example,if the connector 20,22 is molded as part of the first layer 12, wherethe first layer 12 comprises a poly(methyl methacrylate) and where thesecond layer 32 comprises an acrylonitrile-butadiene-acrylonitrilecopolymer, the connector 20,22 can be laser welded to the second layer32.

Likewise, the connector 20,22 can comprise any material that willprovide the desired adhesion between the first layer 12 and the secondlayer 32, for example, the connector 20,22 can comprise an acrylic(e.g., acrylic tape or acrylic foam tape) or an acetate (e.g., ethylenevinyl acetate (EVA)) foam tape. In other words, the connector 20,22 canbe any adhesive having sufficient structural integrity and compatibilitywith the first layer 12 and the second layer 32 to inhibit delamination.For example, the adhesive tape can have an adhesive strength of greaterthan or equal to 0.1 megaPascals (MPa), or, more specifically, greaterthan or equal to 0.2 MPa, as determined in accordance with ISO 4587-1979(Adhesives—Determination of tensile lap shear strength of high strengthadhesive bonds). The elongation at break of the adhesive tape can begreater than or equal to 50%, or, more specifically, greater than orequal to 80%, or, even more specifically, greater than or equal to 95%,as measured in accordance with ISO 4587-1979 (Adhesives—Determination oftensile lap shear strength of high strength adhesive bonds).

The connector 20,22 can act to form a gap between the first layer 12 andthe second layer 32, into which a curable filling can be inserted (e.g.,poured). The connector 20,22 can have a thickness of 0.5 to 10millimeters (mm), or, more specifically, 1.0 to 5.0 mm, and even morespecifically, 2.5 to 3.5 mm. The connector 20,22 can have a width thatis less than or equal to 50% of a total surface area of the layer (e.g.,the layer to which it is applied), or, more specifically, 1% to 40% ofthe total surface area, and, yet more specifically, 2% to 20% of thetotal surface area. The connector 20,22 can be located in the outer 40%of the first layer and/or the second layer (measuring from a center ofthe respective layer toward the edge of the respective layer), or, morespecifically, in the outer 25%, and yet more specifically, in the outer10%. For example, if the layer has a width of 1.0 meter (m), theconnector 20,22 could be located between the outer edge and 0.4 m fromthe outer edge, or, more specifically, between the outer edge and 0.25 mfrom the outer edge, and yet more specifically, between the outer edgeand 0.05 m from the outer edge.

The first layer, the second layer, and the third layer can be made ofthe same or different materials and can each independently comprise apolymeric material, e.g., a thermoplastic material. The thermoplasticmaterial can comprise oligomers, polymers, ionomers, dendrimers,copolymers such as block copolymers, graft copolymers, star blockcopolymers, random copolymers, and combinations comprising at least oneof the foregoing having the desired optical properties for a PVapplication. Examples of such thermoplastic materials include, but arenot limited to, polycarbonates (e.g., blends of polycarbonate (such aspolycarbonate-polybutadiene blends), and copolycarbonates (such ascopolyester-polycarbonates)), polystyrenes (e.g., copolymers ofpolycarbonate and styrene, acrylonitrile-styrene-butadiene copolymers,and acrylonitrile-styrene-acrylonitrile (ASA) copolymers),poly(phenylene ether)-polystyrene resins, polyalkylmethacrylates (e.g.,polymethacrylates, poly(methyl methacrylates) (PMMA)), polyesters (e.g.,copolyesters, polythioesters), polyolefins (e.g., polypropylenes andpolyethylenes, high density polyethylenes, low density polyethylenes,linear low density polyethylenes), polyamides (e.g., polyamideimides),polyethers (e.g., polyether ketones, polyether etherketones,polyethersulfones), and combinations comprising at least one of theforegoing.

More particularly, the thermoplastic material used in one or more of thefirst layer, the second layer, or the third layer can include, but arenot limited to, polycarbonate resins (e.g., LEXAN™ resins, commerciallyavailable from SABIC's Innovative Plastics business, specifically LEXAN™SLX2071T or LEXAN™ LUX2660T), poly(methyl methacrylate resins (e.g.ALTUGLAS™ HT121, commercially available from ARKEMA Inc.), polyphenyleneether-polystyrene resins and/or polyphenylene oxide resins (e.g., NORYL™resins (specifically NORYL™ 6850H or PPX7110), commercially availablefrom SABIC's Innovative Plastics business), polyetherimide resins (e.g.,ULTEM™ resins, commercially available from SABIC's Innovative Plasticsbusiness), polybutylene terephthalate-polycarbonate resins (e.g., XENOY™resins, commercially available from SABIC's Innovative Plasticsbusiness), copolyestercarbonate resins (e.g. LEXAN™ SLX resins,commercially available from SABIC's Innovative Plastics business),polypropylene resins (e.g. 83MF10-10200, commercially available fromSABIC's Innovative Plastics business) and combinations comprising atleast one of the foregoing resins. Even more particularly, thethermoplastic resins can include, but are not limited to, homopolymersand copolymers of: a polycarbonate, a polyester, a polyacrylate, apolyamide, a polyetherimide, a polyphenylene ether, or a combinationcomprising at least one of the foregoing resins. The polycarbonate cancomprise copolymers of polycarbonate (e.g., polycarbonate-polysiloxane,such as polycarbonate-polysiloxane block copolymer), linearpolycarbonate, branched polycarbonate, end-capped polycarbonate (e.g.,nitrile end-capped polycarbonate), and combinations comprising at leastone of the foregoing, for example a combination of branched and linearpolycarbonate. The polycarbonate can comprise a copolymer ofpolycarbonate, for example apolycarbonate/acrylonitrile-styrene-acrylonitrile resin (such as GELOY™XTPMFR15 or GELOY™ HRA222F, commercially available from SABIC'sInnovative Plastics business). The thermoplastic resin can comprise a PA12 resin (such as GRILAMID™ TR90UV, available from EMS GRIVORY).

The first layer can comprise poly(methyl methacrylate), polycarbonate,or a combination comprising one or both of the foregoing and the secondand third layers can each independently comprise anacrylonitrile-styrene-acrylonitrile copolymer, apolycarbonate-acrylonitrile-styrene-acrylonitrile copolymer,poly(phenylene oxide), polypropylene, or a combination comprising one ormore of the foregoing. For example, the first layer can comprisepoly(methyl methacrylate) and the second and third layers can comprisean acrylonitrile-styrene-acrylonitrile copolymer. The second and thirdlayers can, optionally, comprise the same polymer that can be differentfrom that of the first layer.

One or more of the first, second, and third layers can include variousadditives ordinarily incorporated into polymer compositions of thistype, with the proviso that the additive(s) are selected so as to notsignificantly adversely affect the desired properties of the PV moduleassembly, in particular, energy yield and weight savings.

Examples of additives that can be included in the materials used to makethe various layers of the PV module assembly include, but are notlimited to, optical effects filler, impact modifiers, fillers,reinforcing agents, antioxidants, heat stabilizers, light stabilizers,ultraviolet (UV) light stabilizers, plasticizers, lubricants, moldrelease agents, antistatic agents, colorants (such as titanium dioxide,carbon black, inorganic dyes, and organic dyes), surface effectadditives, radiation stabilizers (e.g., infrared absorbing), gammastabilizer, flame retardants, and anti-drip agents. A combination ofadditives can be used, for example a combination of a heat stabilizer,mold release agent, and ultraviolet light stabilizer. In general, theadditives are used in the amounts generally known to be effective. Eachof these additives can be present in amounts of 0.0001 to 10 weightpercent (wt. %), specifically 0.001 to 5 wt. %, based on the totalweight of the layer in which the additive is incorporated. Whenadditives are present, additives can be added such that, for example,the second layer is white, for example to improve optical performance,and/or the third layer is black, for example to improve heat transfer.

One or more of the first, second, and third layers can optionallycomprise a flame retardant. Flame retardants include organic and/orinorganic materials. Organic compounds include, for example, phosphorus,sulphonates, and/or halogenated materials (e.g., comprising brominechlorine, and so forth, such as brominated polycarbonate).Non-brominated and non-chlorinated phosphorus-containing flame retardantadditives can be preferred in certain applications for regulatoryreasons, for example organic phosphates and organic compounds containingphosphorus-nitrogen bonds.

Inorganic flame retardants include, for example, C₁₋₁₆ alkyl sulfonatesalts such as potassium perfluorobutane sulfonate (Rimar salt),potassium perfluorooctane sulfonate, tetraethyl ammonium perfluorohexanesulfonate, and potassium diphenylsulfone sulfonate (e.g., KSS); saltssuch as Na₂CO₃, K₂CO₃, MgCO₃, CaCO₃, and BaCO₃, or fluoro-anioncomplexes such as Li₃AlF₆, BaSiF₆, KBF₄, K₃AlF₆, KAlF₄, K₂SiF₆, and/orNa₃AlF₆. When present, inorganic flame retardant salts are present inamounts of 0.01 to 10 parts by weight, more specifically 0.02 to 1 partsby weight, based on 100 parts by weight of the total composition of thelayer of the PV module assembly 10 in which it is included (i.e., thefirst layer 12, the second layer 32, or the third layer 36), excludingany filler.

Anti-drip agents can also be used in the composition forming one or moreof the first, second, and third layers, for example a fibril formingfluoropolymer such as polytetrafluoroethylene (PTFE). The anti-dripagent can be encapsulated by a rigid copolymer, for examplestyrene-acrylonitrile copolymer (SAN). PTFE encapsulated in SAN is knownas TSAN. An exemplary TSAN comprises 50 wt. % PTFE and 50 wt. % SAN,based on the total weight of the encapsulated fluoropolymer. The SAN cancomprise, for example, 75 wt. % styrene and 25 wt. % acrylonitrile basedon the total weight of the copolymer. Anti-drip agents can be used inamounts of 0.1 to 10 parts by weight, based on 100 parts by weight ofthe total composition of the particular layer, excluding any filler.

One or more of the first, second, and third layers can additionallycomprise a silicone hardcoat and/or a plasma deposition layer, forexample, on the outermost surface of the first layer 12 and/or the thirdlayer 36 to potentially ensure a 20 year lifetime span for the PV moduleassembly.

It can be desirable for one or more of the first, second, and thirdlayers to have certain optical properties. For example, the first layercan be transparent, the second layer can be transparent,semi-transparent, or opaque, and the third layer can be opaque orsemitransparent, or transparent. With regards to the transparency of thevarious layers, it is briefly noted that end user specifications cangenerally specify that the various layers satisfy a particularpredetermined threshold. Haze values, as measured by ANSI/ASTM D1003-00,can be a useful determination of the optical properties of one or moreof the first, second, and third layers. The lower the haze levels, thehigher the transparency of the individual layer. It can be desirable tomonitor the haze levels of the various layers. Exemplary haze levels forthe transparent first layer, when measured at a thickness of 5.0 mm, canbe 0% to 6%, specifically 0.5% to 4%, and more specifically 1% to 2.5%.Exemplary haze levels for the second layer, when measured at a thicknessof 5.0 mm, can be generally greater than 6%, specifically, greater thanor equal to 10%. The first layer can have a transparency of greater thanor equal to 80%, specifically, greater than or equal to 85%, morespecifically, greater than or equal to 90%, even more specifically,greater than or equal to 95%, and still more specifically, greater thanor equal to 99%, as measured in accordance with ASTM D1003-00, ProcedureA or Procedure B, using lamp D65. The second and/or third layer can besemi-transparent, but can also be transparent or opaque if desired, forexample, for aesthetic reasons. For example, the second and/or thirdlayer can have a transparency of greater than or equal to 50%,specifically, greater than or equal to 65%, more specifically, greaterthan or equal to 75%, and even more specifically, greater than or equalto 90%. Transparency is described by two parameters, percenttransmission and percent haze. Percent transmission and percent haze forlaboratory scale samples can be determined using ASTM D1003-00,Procedure B using CIE standard illuminant C. ASTM D-1003-00 (ProcedureB, Spectrophotometer, using illuminant C with diffuse illumination withunidirectional viewing) defines transmittance as:

$\begin{matrix}{{\% \mspace{14mu} T} = {\left( \frac{I}{I_{o}} \right) \times 100\%}} & (1)\end{matrix}$

-   -   wherein: I=Intensity of the light passing through the test        sample        -   I_(o)=Intensity of incident light.            Haze can be measured in accordance with ASTM D-1003-00,            Procedure A, measured, e.g., using a HAZE-GUARD DUAL from            BYK-Gardner, using and integrating sphere (0°/diffuse            geometry), wherein the spectral sensitivity conforms to the            CIE standard spectral value under standard lamp D65. ASTM            D1003-00, Procedure B can also use a Macbeth 7000A            spectrometer, D65 illuminant, 10° observer, CIE (Commission            Internationale de L'Eclairage) (1931), and SCI (specular            component included), and UVEXC (i.e., the UV component is            excluded); while haze uses the same variables with            Procedure A. It is noted that the percent haze can be            predicted and calculated from the following equation:

$\begin{matrix}{{\% \mspace{14mu} {Haze}} = {100 \times \frac{{Total}\mspace{14mu} {Diffuse}\mspace{14mu} {Transmission}}{{Total}\mspace{14mu} {transmission}}}} & (2)\end{matrix}$

wherein total transmission is the integrated transmission; and the totaldiffuse transmission is the light transmission that is scattered by thefilm as defined by ASTM D1003-00. For example, a commercially availablehazemeter can be used, such as the BYK-Gardner Haze-Gard Plus, with therough diffusing side of the film facing the detector.

It can be desirable for the refractive index of the first layer and thesecond layer to be close to (e.g., within 20%) the refractive index ofthe cured composition; it can also be desirable for the coefficient ofthermal expansion of the first layer and the second layer to be close(e.g., within 15% of each other). Further, it can be desirable for thePV module assembly to pass the impact test requirements as set forth inUL 1703. Flame retardance as tested according to the standard of theUnderwriters Laboratory 94 (UL 94) of the layers can be another factorto consider when selecting materials for the first layer, the secondlayer, and the third layer. For example, the UL 94 rating shoulddesirably be VO or greater (e.g., 5 VB or 5 VA). One or more of thefirst, second, and third layers can also desirably have an ultravioletlight stability of 20 years such that they retain greater than or equalto 80% of their light transmission capabilities over that 20 yearperiod.

Turbulent airflow, which functions to cool the PV module, can be createdby aerodynamic features integrated in the back layer. The first layercan also, optionally, be textured to decrease light reflection. Both theturbulent air flow and the texturing can provide higher energy yieldduring a PV module's lifetime under different circumstances, such assunlight entering at an angle, high ambient temperatures, and partialshading of the PV module. For example, the aerodynamic features caninclude, but are not limited to fins, ribs, baffles, and combinationscomprising at least one of the foregoing. Turbulent air flow andtexturing, when integrated into a PV module can reduce cost, decreaseproduction times, and reduce the weight of the PV module as well asoptimize the yield of a system during its useful lifetime.

The back layer 30 can comprise a frame, a junction box, cables,connectors, mounting points for mounting to an external structure, andan inverter (e.g., a micro-inverter). Integration of all of thesecomponents into the back layer 30 can offer significant savings inproduction time, assembly time, and cost compared to a PV module whereeach component is produced separately and has to be assembled afterproduction.

Generally, PV modules comprise a top layer made of glass that canfunction to impart rigidity to the module and a back layer, where thematerial of the back layer generally does not function to impartrigidity to the module. Typically, the glass top layer is 3.2millimeters (mm) thick. As described herein, the glass top layer can bereplaced with a layer comprising a thermoplastic material that canresult in significant weight savings for the PV module assembly. Thethickness of the first layer, the second layer, and the third layer canbe, individually, 0.5 to 25 mm, specifically, 1 to 8 mm, even morespecifically, 1 to 3.2 mm, specifically, 1 to 1.5 mm. The thickness ofthe first, second, and third layers can be the same or different.

It was surprisingly discovered that a support layer 34 can be added tothe back layer 30 of a PV module 10 in order to increase the mechanicalproperties of the PV module when the glass top layer is replaced with alayer comprising a thermoplastic material. For example, the supportlayer 30 can be located between the second 32 and third layers 36 (seee.g., FIG. 1) such that the thickness of the back layer is 2 to 60 mm,specifically 5 to 40 mm, even more specifically 10 to 25 mm thick. Acombined thickness of the second 32 and third layers 36 can be less thanor equal to 1 mm thick.

The support layer 30 can comprise a stiffening element configured toimprove the stiffness and/or impact properties of the PV module 10. Forexample, the stiffening element can comprise vertical stiffeningelement(s) 60 which extend in a z direction, horizontal stiffeningelement(s) 62 which extend in an x direction, diagonal stiffeningelement(s) 64 which extend between a z and x direction, or a combinationcomprising one or more of the foregoing (see FIG. 5). The stiffeningelement can be straight, curved, or jagged. The geometry formed by thestiffening elements defines the openings 38 in the support layer. Theseopenings can have various cross-sectional geometries (in the x-z plane)including polygonal and/or rounded, such as round, oblong, multi-sided,and combinations comprising at least one of the foregoing. For example,the multi-sided cross-sectional geometry can be triagonal, quatragonal,pentagonal, hexagonal (e.g., honeycomb), heptagonal, octagonal, and thelike. In other words, the openings 38 are defined by greater than orequal to 3 stiffening elements such that each opening has greater thanor equal to 3 sides.

The openings 38 extend in the y direction forming channels 39. In otherwords, the channels 39 extend in a direction perpendicular to the length“l” of the layers.

The support layer can be formed of stiffening elements 24 and openingssuch that it has an array pattern, where the array pattern can beobserved in the cross-section taken along line A-A (in the x-z plane) asillustrated in FIG. 1. For example, the array pattern can comprise ahoneycomb array 40, a triangular array 42, an R6 array 44, a hexakisarray 46, and the like (see FIGS. 2-5, respectively). The R6 array 44 isa combination of multi-sided opening geometries (also referred to ascells), e.g., a combination of 3 sided and 6 sided geometries. Thehexakis array 46 includes an arrangement of triangles such that 12stiffening elements 48 extend radially from a point 50 to stiffeningelements 52 to form a six sided structure 54. The opening density can be10 to 1,500 or more openings per 100 square centimeters (cm²),specifically, 100 to 1,000 openings per 100 cm², and more specifically150 to 700 openings per 100 cm². Generally, a support layer willcomprise greater than or equal to 10 openings, specifically, greaterthan or equal to 50 openings, more specifically, greater than or equalto 100 openings, and still more specifically, greater than or equal to1,000 openings.

The support layer 34 can comprise, for example the honeycomb THERMHEX™core material, commercially available from ECONCORE N.V. and can beformed by a thermoforming, folding, and bonding process, extrusion, orotherwise.

The support layer 34 can be 1 to 35 mm, specifically 4 to 16 mm, andmore specifically, 5 to 15 mm thick (as measured in the y direction).

The support layer can comprise one or more of the polymers previouslydescribed with respect to the first layer, second layer, and/or thirdlayer, as well as one or more of the previously described additives.Specifically, the support layer can comprise polypropylene,polyethylene, polystyrene, polyethylene terephthalate, polyamide,polycarbonate, acrylonitrile-butadiene-styrene,acrylonitrile-styrene-acrylonitrile, polyurethane, polyphenylenesulfide, polyetherimide, or a combination comprising one or more of theforegoing.

As illustrated in FIG. 1, the support layer 34 can comprise a supportfirst side 33 and/or a support second side 35. Optionally, the supportlayer 34 can further comprise a first and/or a second skin that can bebonded to the support first side 33 and/or the support second side 35 ofthe support layer 34. The skin material can be the same or differentfrom the support layer.

The support layer 34 can comprise openings 38 as illustrated in FIG. 2.The openings 38 can be unfilled (i.e., a void space) or can be filled toprovide extra support. The openings 38 can be filled with, for example,a foam (such as a polyurethane foam, a polyimide foam such as apolyetherimide foam for example ULTEM™ resin, a polystyrene foam such asSTYROFOAM™, a silicone foam, or a polyvinyl chloride foam). The openings38 extend through the support layer 34, e.g., between the second layer32 and the third layer 36. Optionally, the openings can extend from thesecond layer 32 to the third layer 36.

The PV layer 16 of the PV module 10 can comprise a cured composition anda PV cell 14 (see e.g., FIG. 1). The cured composition can be one thatis thermally cured, cured by ultraviolet (UV) radiation, catalyst cured,or can naturally cure when one or more reactive monomers are present.The cured composition can comprise, for example, poly(ethylene vinylacetate) (EVA), a curable silicone (such as a silicone thermosetelastomer (TSE), a UV curable silicone, or a room temperature vulcanize(RTV) silicone), thermoplastic materials (such as aliphaticpolyurethanes and/or polyolefin ionomers), and combinations comprisingat least one of the foregoing. The thickness of the PV layer can be 0.5to 10 mm, specifically, 1 to 5 mm, and even more specifically, 2 to 3.5mm. Optionally, the thickness of the PV layer can be the same as thethickness of the connector.

FIG. 1 illustrates that PV cells 14 can be located within the PV layer16. Examples of PV cells include monocrystalline silicon,polycrystalline silicon, amorphous silicon, silicon tandem cells, copperindium gallium selenide (CIGS), cadmium telluride (CdTe), and organiccells, as well as combinations comprising at least one of the foregoing.The various types of cells have different demands for moistureprotection varying from protection against only liquid water to highlyeffective protection from water vapor making the moisture barrieroptional.

A PV cell can be formed of layers of p-i-n semiconductive material.Optionally, each layer of which can, in turn, be formed of, asemiconductor alloy material (e.g., a thin film of such alloy material).In one embodiment, a p-i-n type PV device, such as a solar cell, cancomprise individual p-i-n type cells. Below the lowermost cell can be asubstrate (e.g., a transparent substrate) or a substrate comprising ametallic material such as stainless steel, aluminum, tantalum,molybdenum, chrome, or metallic particles embedded within an insulator(cermets). In some applications there is a thin oxide layer and/or aseries of base contacts prior to the deposition of the amorphoussemiconductor alloy material.

Each of the cells can be fabricated from a body of thin filmsemiconductor alloy material comprising silicon and hydrogen. Each ofthe bodies of semiconductor alloy material includes an n-type layer ofsemiconductor alloy material; a substantially intrinsic layer ofsemiconductor alloy material; and a p-type layer of semiconductor alloymaterial. The intrinsic layer can include traces of n-type or p-typedopant material without forfeiting its characteristic neutrality, henceit may be referred to as a “substantially intrinsic layer”.

Also, although p-i-n type photovoltaic cells are described, the methodsand materials can also be used to produce single or multiple n-i-p typesolar cells, p-n type cells or devices, Schottky barrier devices, aswell as other semiconductor elements and/or devices such as diodes,memory arrays, photoresistors, photodetectors, transistors, etc. Theterm “p-i-n type”, as used herein, is defined to include any aggregationof n, i, and p layers operatively disposed to provide a photoresponsiveregion for generating charge carriers in response to absorption ofphotons of incident radiation.

The PV cell 14 converts the light energy into electrical energy. Severaldifferent types of PV cells 14 can be used. Suitable bulk technology PVcells 14 include amorphous silicon cells, multicrystalline siliconcells, and monocrystalline silicon cells. Suitable thin film technologyPV cells 14 include cadmium telluride cells, copper indium selenidecells, gallium arsenide or indium selenide cells, and copper indiumgallium selenide cells. In specific embodiments, the PV cell is amulticrystalline silicon PV cell or a monocrystalline silicon PV cell.

Generally, each type of PV cell has a “sweet spot”, or a range ofwavelengths (light energy), which it converts most efficiently intoelectric energy. The PV cell should be selected so that its sweet spotmatches, as much as possible, the transmitted light through the optionalcoating, first layer, and cured composition combination. For example,the sweet spot of a multicrystalline silicon photocell or amonocrystalline silicon PV cell is 700 nanometers to 1100 nanometers.The PV cell can be selected such that it can harvest UV light with awavelength of 200 to 400 nm.

The efficiency of a PV cell can be affected by the way the cell isproduced. When PV cells are produced by cutting using a 30 micrometerdiamond saw compared to laser guided water cutting, the PV cell mayincrease its efficiency by 1%. For example, PV cells can be producedusing a DISCO DAD 321 cutter (available from Disco Corporation)operating at 30,000 rpm. See also U.S. Pat. No. 4,097,310, thedisclosure of which is hereby fully incorporated by reference herein.Generally, it is desirable for the PV cell to have smooth edges andfaces rather than rough edges and faces. The size (e.g., length andwidth) and shape of the PV cells can vary. Shapes can include variouspolygonal designs such as square, rectangular, and so forth. The lengthand width can, individually be up to 200 mm, specifically, 100 mm to 175mm. Exemplary sizes include 100 mm by 100 mm, 125 mm by 125 mm, 150 mmby 150 mm, 156 mm by 156 mm, 175 mm by 175 mm, and 200 mm to 200 mm, 100mm by 175 mm, and 125 mm by 150 mm.

The cured composition can additionally aid in transporting heat out ofthe PV cells to the atmosphere, resulting in higher efficiency for thePV module over time. As described previously, the back layer can befully integrated with other features of the PV module assemblyincluding, but not limited to the junction box, mounting points, andmicro-inverter. A turbulent airflow to cool the PV module can be createdby aerodynamic features integrated in the back layer. The aerodynamicfeatures can include, but are not limited to, fins, ribs, baffles, andcombinations comprising at least one of the foregoing. The first layercan optionally be textured to decrease light reflection away from the PVmodule, thereby increasing solar absorption of the PV module. Such adesign with a textured first layer and/or aerodynamic features in theback layer can allow for a higher energy yield during a PV module'slifetime under different circumstances such as sunlight that enters atan angle, high ambient temperatures, and partial shading.

As mentioned, the replacement of a glass layer in a PV module canadvantageously result in a decrease in the overall weight of the PVmodule, but can also result in a decrease in the stiffness and/orflexural strength. It was unexpectedly found that a support layer,specifically a support layer as described herein comprising stiffeningelements, can result in an increase in one or both of the stiffnessand/or flexural strength without significantly increasing the totalweight of the module. Specifically, the first, second, and third layerscan each, independently, comprise a plastic material and the back layercan additionally comprise an integrated assembly including the junctionbox, cables, controllers, and mounting points, meaning that theproduction time and assembly time of the PV module assembly can bedecreased.

As mentioned, the first layer can comprise a plastic material, such aspoly(methyl methacrylate), polycarbonate, polyamide, and combinationscomprising at least one of the foregoing. Using a plastic material forthe first layer can allow for the incorporation of optical textures suchas Fresnel lenses to increase the amount of light captured.Incorporating features such as triangles on a surface of the first layeradjacent to the photovoltaic layer can capture light between the PVcells that would normally be lost. As previously mentioned, aerodynamicfeatures integrated in the second layer create turbulent airflow on asurface of the second layer facing the structure to which the PV moduleassembly is attached (e.g., roof). The turbulent air flow can allow thePV cells to operate at lower temperatures, thus increasing theefficiency of the PV module. The curable composition can be selected sothat the refractive index (RI) of this layer is close in value to the RIof the first layer, thus limiting the light lost between the curedcomposition and the first layer and further increasing the efficiency ofthe PV module. For example, the RI of PMMA is 1.49 and the RI of a curedsilicone is 1.4. The refractive index of the material of the first layercan be within 15% of the refractive index of the material of the curablecomposition.

The overall size of the module is a function of the process used to makethe module, such as injection molding. The overall size of the modulecan be, for example, 1 by 1 meter (m) or 1 by 2 m, or 1 by 6 m. Aspreviously described, the size of the individual PV cells in the modulecan be, for example, 125 by 125 mm, specifically 156 by 156 mm.

The PV module can also comprise a first layer having a coating dispersedon the outermost surface of the first layer, e.g., a silicone hardcoatand/or a plasma coating. The plasma coating (e.g., EXATEC™ E900 coating,commercially available from EXATEC LLC) can help to ensure the PV modulecan function for a certain period of time, e.g., 20 years. When one ofthe layers comprises, for example, polycarbonate, said layer cancomprise planarizing layer(s) and/or organic-inorganic compositionbarrier coating layer(s) which can include a silicone hardcoat and/or aplasma treatment process. The barrier coating (which can be graded ornon-graded) can comprise a zone substantially organic in composition anda zone substantially inorganic in composition. Some exemplaryorganic-inorganic composition barrier coatings are described in U.S.Pat. No. 7,449,246. Exemplary coating compositions for theorganic-inorganic barrier layer are organic, ceramic and/or inorganicmaterials, as well as combinations comprising at least one of theforegoing. These materials can be reaction or recombination products ofreacting plasma species and are deposited onto the substrate surface.Organic coating materials typically comprise carbon, hydrogen, oxygen,and optionally other elements, such as sulfur, nitrogen, silicon, etc.,depending on the types of reactants. Exemplary reactants that result inorganic compositions in the coating are straight or branched alkanes,alkenes, alkynes, alcohols, aldehydes, ethers, alkylene oxides,aromatics, silicones, etc., having up to 15 carbon atoms. Inorganic andceramic coating materials typically comprise oxide; nitride; carbide;boride; or combinations comprising at least one of the foregoing ofelements of Groups IIA, IIIA, IVA, VA, VIA, VIIA, IB, and IIB; metals ofGroups IIIB, IVB, and VB; and rare-earth metals. For example, thebarrier coating can have optical properties that are substantiallyuniform along an axis of light transmission, said axis orientedsubstantially perpendicular to the surface of the coating.

For example, silicon carbide can be deposited onto a substrate (e.g.,the first, second, or third layer) by recombination of plasmas generatedfrom silane (SiH₄) and an organic material, such as methane or xylene.Silicon oxycarbide can be deposited from plasmas generated from silane,methane, and oxygen or silane and propylene oxide. Silicon oxycarbidealso can be deposited from plasmas generated from organosiliconeprecursors, such as tetraethoxysilane (TEOS), hexamethyldisiloxane(HMDSO), hexamethyldisilazane (HMDSN), or octamethylcyclotetrasiloxane(D4). Silicon nitride can be deposited from plasmas generated fromsilane and ammonia. Aluminum oxycarbonitride can be deposited from aplasma generated from a mixture of aluminum tartrate and ammonia. Othercombinations of reactants may be chosen to obtain a desired coatingcomposition. A graded composition of the coating is obtained by changingthe compositions of the reactants fed into the reactor chamber duringthe deposition of reaction products to form the coating.

The barrier coating can have a transmission rate of oxygen through thebarrier coating of less than or equal to 0.1 cubic centimeters persquare meter-day (cm³/(m² day)), as measured at 25 degrees Celsius (°C.) with a gas containing 21 volume percent (vol %) oxygen. The watervapor transmission can be less than 0.01 grams per square meter-day(g/(m² day)), as measured at 25° C. and with a gas having 100% relativehumidity.

Barrier layer(s) can be applied to polymer films by various methods suchas chemical vapor deposition (e.g., plasma-enhanced chemical-vapordeposition, radio-frequency plasma-enhanced chemical-vapor deposition,expanding thermal-plasma chemical-vapor deposition,electron-cyclotron-resonance plasma-enhanced chemical-vapor deposition,and inductively-coupled plasma-enhanced chemical-vapor deposition),sputtering (e.g., reactive sputtering), and so forth, as well ascombinations comprising at least one of the foregoing. Some such methodsare described in U.S. Pat. No. 7,015,640 and U.S. Patent Publication No.2006/0001040.

The planarizing layer can comprise a resin such as an epoxy based resin(cycloaliphatic resin), an acrylic based resin, a silicone resin, aswell as combinations comprising at least one of the foregoing. Oneexample of a planarizing layer is a UV-cured acrylic-colloidal silicacoating such as the LEXAN™ HP-H UV-cured acrylic-colloidal silicacoating commercially available from the Specialty Film and Sheetbusiness unit of SABIC's Innovative Plastics business. The planarizinglayer, and/or other coatings, can further include additive(s) such asflexibilizing agent(s), adhesion promoter(s), surfactant(s),catalyst(s), as well as combinations comprising at least one of theforegoing. In some embodiments, the planarizing layer thickness can be 1nanometer (nm) to 100 micrometers (μm). Often the planarizing layerthickness can be 100 nm to 10 μm, specifically, 500 nm to 5 μm.

The planarizing layer can be substantially smooth and substantiallydefect free. The term “average surface roughness” R_(a) is defined asthe integral of the absolute value of the roughness profile measuredover an evaluation length. The term “peak surface roughness” R_(p) isthe height of the highest peak in the roughness profile over theevaluation length. The term “substantially smooth” means the averagesurface roughness R_(a) is less than or equal to 4 nm, specifically,less than or equal to 2 nm, and more specifically, less than or equal to0.75 nm. The peak surface roughness R_(p) can be less than or equal to10 nm, specifically less than or equal to 7 nm, and more specifically,less than or equal to 5.5 nm. Substantially defect free means the numberof point defects is less than or equal to 100 per square millimeter(/mm²), specifically, less than or equal to 10/mm², and morespecifically, 1/mm².

Alternatively, one or more of the first, second, and third layers can befree of a coating. For example, when the first layer comprisespoly(methyl methacrylate), the first layer can be free of a coating.

The PV module as a whole can be designed to meet several UnderwritersLaboratory (UL) and International Electrotechnical Commission (IEC)standards. Table 1 lists the various components of the PV moduleassembly and the tests that the each component can be designed to meet.

TABLE 1 PV Module Assembly Components and Standards PV Cells UL 1703,IEC 61215, IEC 61646, IEC 61730, UL 790, UL-SU 8703, IEC 61701, IEC62108 Junction Box UL 1703, UL 746C, IEC 61730-1 Connector UL-SU 6703GFCI UL 1741 Polymeric Materials UL-SU 5703 (e.g., second layer)Mounting System UL-SU 1703-A Tracking System UL-SU 9703 Cable for PVCells UL 4703, UL 854 (USE-2) Combiner Box UL 1741 Inverter UL 1741, IEC61209

The PV cells, for example, can be designed to meet Paragraphs 7.3 and7.4 of UL 1703 Edition 3_2008. Paragraph 7.3 of UL 1703 states that apolymeric substrate or superstrate shall have a thermal index, bothelectrical and mechanical, as determined in accordance with the Standardfor Polymeric Materials—Long Term Property Evaluations, UL 746B, notless than 90° C. (194° F.). In addition, the thermal index shall not beless than 20° C. (36° F.) above the measured operating temperature ofthe material. All other polymeric materials shall have a thermal index(electrical and mechanical) 20° C. above the measured operatingtemperature. The measured operating temperature is the temperaturemeasured during the open-circuit mode for Temperature Test, Section 19,or the temperature during the short-circuit mode, whichever is greater.Paragraph 7.4 states that a polymeric material that serves as the outerenclosure for a module or panel that: a) is intended to be installed ina multi-module or multi-panel system; or b) has an exposed surface areagreater than 10 square feet (ft²) (0.93 square meters (m²)) or a singledimension larger than 6 feet (ft) (1.83 meters (m)) shall have a flamespread index of 100 or less as determined under the Standard Method ofTest for Surface Flammability of Materials Using a Radiant Heat EnergySource, ASTM E162-2001.

The PV module assembly can also be designed to meet the requirements setforth in Paragraph 30 of UL 1703, which describes the impact test. Inorder to pass the test, when a module is impacted as described below,there shall be no accessible live parts as defined in Section 15,Accessibility of Uninsulated Live Parts. Breakage of the superstratematerial is acceptable provided there are no particles larger than 1square in 6.5 square centimeters (cm²) released from their normalmounting position. The impact test is described as follows in Paragraph30.3 of UL 1703, a module or panel is to be mounted in a mannerrepresentative of its intended use, and is to be subjected to a 5 footpound (ft-lb) (6.78 Joule (J)) impact normal to the surface resultingfrom a 2 inch (51 mm diameter smooth steel sphere weighing 1.18 pounds(lb) (535 grams (g)) falling through a distance of 51 inches (1.295 m).The module or panel is to be struck at any point considered mostvulnerable. If the construction of a module or panel does not permit itto be struck free from above by the free falling sphere, the sphere isto be suspended by a cord and allowed to fall as a pendulum through thevertical distance of 51 inches (1.295 m) with the direction of impactnormal to the surface. For a polymeric wiring enclosure, the test is tobe performed on the enclosure at 25° C. (77° Fahrenheit (F)) and alsoafter being cooled and maintained for 3 hours at a temperature of minus35.0±2.0° C. (minus 31.0±3.6° F.).

IEC 61215 Edition 2_2005 provides requirements for the designqualification and type approval of terrestrial photovoltaic modulesappropriate for long term operation in general open air climates.Paragraph 10.11 of IEC 61215 provides a thermal cycling test forphotovoltaic assemblies. The modules are subjected to a thermal cyclingtest where the temperature is cycled from −40° C.±2° C. to 85° C.±2° C.and each cycle is no longer than 6 hours and the total cycle time is1,000 hours. The photovoltaic module assemblies disclosed herein canmaintain greater than or equal to 95% of the maximum power output afterbeing exposed to a thermal cycling of −40° C.±2° C. to 85° C.±2° C. for1,000 hours. Paragraph 10.12 of IEC 61215 provides a humidity-freezetest to determine the ability of the module to withstand the effects ofhigh temperature and humidity followed by sub-zero temperatures. Themodules are subject to a cycle of 85% relative humidity ±5% for 20minutes and a recovery time of 2 to 4 hours. Ten such cycles areperformed before the module is evaluated to determine if the maximumoutput power has decreased greater than 5% compared to the valuemeasured before the test. If so, the module is considered to have failedthe test. Paragraph 10.13 of IEC 61215 provides a damp heat test carriedout in a climatic chamber capable to carry out the test in accordancewith IEC 60068-2-3 at conditions of 85° C.±2° C. with an 85% relativehumidity ±5%. The purpose of this test is to determine the ability ofthe module to withstand long term exposure to penetration of humidity byapplying the conditions described above for 1,000 hours. The severity ofthis test particularly challenges the lamination process and the edgesealing from humidity. Delamination and corrosion of cell parts can beobserved as a result of humidity penetration.

IEC 61646 Edition 2_2008 provides requirements for the designqualification and type approval of terrestrial thin film photovoltaicmodules appropriate for long term operation in general open air climatesas defined in IEC 60721-2-1. IEC 62108 describes the minimumrequirements for the design qualification and type approval ofconcentrator photovoltaic modules and assemblies appropriate for longterm operation in general open air climates as defined in IEC 60721-2-1.IEC 61701 determines the resistance of the module to corrosion from saltmist, looking at highly corrosive wet atmospheres, such as marineenvironments and temporary corrosive atmospheres that are also presentin places where salt is used in winter periods to melt ice formations onstreets and roads.

The PV module assembly disclosed herein can be designed to weighapproximately 5 kg/m² compared to 13 kg/m² for PV modules containing aglass first layer and/or aluminum frame. The layers of the PV module canbe formed from a thermoplastic composition by a variety of techniquessuch as injection molding, extrusion, rotational molding, blow molding,and thermoforming. Forming can be accomplished by injection molding.Injection molding allows for a mass producible module withoutnecessitating the laminating process used in modules containing a glassfirst layer. As a result, the assembly time for the PV module candecrease from greater than or equal to 20 minutes to 1 minute to 5minutes, specifically, 2 minutes to 3 minutes. Installation of the PVmodule assembly can be easier and less time consuming since the PVmodule is lighter and as mentioned, incorporates integrated mountingpoints which allow for easy installation. Additionally, the use ofmicro-inverters can allow the system to be a plug and play without theneed for a separate inverter installation step. The overall cost of thePV module assembly can be decreased by 10% due to the faster assemblytime and shorter installation time partly because of the integration ofthe junction box and inverter. Overall yield of the module due, forexample, to partial shading, imperfect placement of the modules, or highambient temperature, will be higher compared to other modules, furtherdecreasing the cost of the PV module by 20%. For example, the overallyield of the module can be greater than or equal to 10% higher comparedto other modules, specifically, greater than or equal to 20% higher,more specifically, greater than or equal to 25%, even more specifically,greater than or equal to 50%, and still more specifically, greater thanor equal to 75% higher. One or more of the first, second, and thirdlayers can be reground and reused in a new layer or structural supportpart.

The PV module assemblies can be used in solar power generationapplications in various manners such as building facades, on rooftops(such as a skylight or roofing tile), in highway/railroad soundbarriers, greenhouses, dual purpose window glazing, and commercialbuildings.

Set forth below are some embodiments of the PV module assembliesdisclosed herein.

Embodiment 1

A photovoltaic module assembly, comprising: a polymeric first layer; aback layer, wherein the back layer comprises a polymeric second layer, apolymeric third layer, and a polymeric support layer located between thesecond layer and the third layer; and a photovoltaic layer comprisingphotovoltaic cells, wherein the photovoltaic layer is located betweenthe first layer and the back layer; wherein the support layer comprisesstiffening elements that define openings that extend in a y directionthat is perpendicular to a length of the first layer.

Embodiment 2

The photovoltaic module assembly of Embodiment 1, wherein the stiffeningelement comprises a vertical stiffening element, a horizontal stiffeningelement, a diagonal stiffening element, or a combination comprising oneor more of the foregoing.

Embodiment 3

The photovoltaic module assembly of any of Embodiments 1-2, wherein thestiffening element comprises a honeycomb array, a triangular array, anR6 array, a hexakis array, or a combination comprising one or more ofthe foregoing.

Embodiment 4

The photovoltaic module assembly of any of Embodiments 1-3, wherein thestiffening element comprises a honeycomb array.

Embodiment 5

The photovoltaic module assembly of any of Embodiments 1-4, wherein thesupport layer comprises openings, wherein the openings are filled.

Embodiment 6

The photovoltaic module assembly of any of Embodiments 1-5, wherein thesupport layer has a thickness of 1 to 35 mm.

Embodiment 7

The photovoltaic module assembly of any of Embodiments 1-6, wherein thephotovoltaic module has an increased stiffness and/or an increasedflexural strength as compared to a photovoltaic module that does notcomprise the support layer.

Embodiment 8

The photovoltaic module assembly of any of Embodiments 1-7, wherein thefirst layer, the second layer, and the third layer each independentlycomprise a thermoplastic material.

Embodiment 9

The photovoltaic module assembly of any of Embodiments 1-8, wherein thefirst layer comprises poly(methyl methacrylate), polycarbonate, or acombination comprising one or both of the foregoing.

Embodiment 10

The photovoltaic module assembly of any of Embodiments 1-9, wherein thefirst layer comprises poly(methyl methacrylate) and is free from acoating.

Embodiment 11

The photovoltaic module assembly of any of Embodiments 1-10, wherein athickness of the first layer, the second layer, and the third layer iseach independently 0.5 to 25 mm.

Embodiment 12

The photovoltaic module assembly of Embodiment 11, wherein the thicknessof the first layer is 1.2 to 1.5 mm.

Embodiment 13

The photovoltaic module assembly of any of Embodiments 1-12, wherein thesecond layer and/or the third layer comprise anacrylonitrile-styrene-acrylonitrile copolymer, apolycarbonate-acrylonitrile-styrene-acrylonitrile copolymer,poly(phenylene oxide), polypropylene, or a combination comprising one ormore of the foregoing.

Embodiment 14

The photovoltaic module assembly of any of Embodiments 1-13, wherein thefirst layer comprises poly(methyl methacrylate) and the second layerand/or the third layer comprise an acrylonitrile-styrene-acrylonitrilecopolymer.

Embodiment 15

The photovoltaic module assembly of any of Embodiments 1-14, furthercomprising a connector.

Embodiment 16

The photovoltaic module assembly of Embodiment 15, wherein the connectoris part of the first layer.

Embodiment 17

The photovoltaic module assembly of any of Embodiments 15-16, whereinthe connector is welded to the first layer and/or the second layer.

Embodiment 18

The photovoltaic module assembly of any of Embodiments 1-17, wherein thefirst layer has one or both of a haze level of 0% to 6% when measured ata thickness of 5.0 mm or a transparency of greater than or equal to 80as measured in accordance with ASTM D1003-00, Procedure A or ProcedureB, using lamp D65.

Embodiment 19

The photovoltaic module assembly of any of Embodiments 1-18, wherein thesecond layer and/or the third layer is opaque.

Embodiment 20

The photovoltaic module assembly of any of Embodiments 1-19, wherein thesecond layer is white.

Embodiment 21

The photovoltaic module assembly of any of Embodiments 1-20, wherein thethird layer is black.

Embodiment 22

The photovoltaic module assembly of any of Embodiments 1-21, wherein thephotovoltaic layer further comprises a cured composition.

Embodiment 23

The photovoltaic module assembly of Embodiment 22, wherein the curedcomposition is thermally cured, cured by ultraviolet radiation, orcatalyst cured.

Embodiment 24

The photovoltaic module assembly of any of Embodiments 22-23, whereinthe cured composition comprises a cured silicone that is an ultravioletcured silicone or a thermally cured silicone.

Embodiment 25

The photovoltaic module assembly of any of Embodiments 1-24, wherein thephotovoltaic layer has a thickness of 0.5 to 10 mm.

The PV module assemblies as described herein are further illustrated bythe following non-limiting examples.

EXAMPLES Example 1

The effect of the incorporation of the support layer into the back layeron the stiffness, the flexural strength, and the overall weight wasdetermined. Sample A was a solid material of a thickness t (see FIG. 6).Sample B was a back layer comprising a second layer 32, a support layer34 with a hexagonal array stiffening element, and a third layer 36,where the thickness of the second and third layers is one half that ofthe thickness of the solid material of Sample A and the overallthickness of the back layer is twice that of Sample A (see FIG. 7).Sample C was a back layer comprising a second layer 32, a support layer34 with a hexagonal array stiffening element, and a third layer 36,where the thickness of the second and third layers is one half that ofthe thickness of the solid material of Sample A and the overallthickness of the back layer is four times that of Sample A (see FIG. 8).The relative stiffness, the relative flexural strength, the sampleweight, and the relative weight are found in Table 2, where the relativevalues are relative to Sample A.

TABLE 2 Sample A B C Relative Stiffness 1.0 7.0 37.0 Relative FlexuralStrength 1.0 3.5 9.2 Weight (pounds per square foot) 0.910 0.978 0.994Relative Weight 1.0 1.03 1.06

Table 2 shows the presence of the support layer results in an increasein both the stiffness and the flexural strength and that increasing thethickness of said layer results in further increases of the mechanicalproperties, while maintaining a low relative weight.

All ranges disclosed herein are inclusive of the endpoints, and theendpoints are independently combinable with each other (e.g., ranges of“up to 25 wt. %, or, more specifically, 5 wt. % to 20 wt. %”, isinclusive of the endpoints and all intermediate values of the ranges of“5 wt. % to 25 wt. %,” etc.). “Combination” is inclusive of blends,mixtures, alloys, reaction products, and the like. Furthermore, theterms “first,” “second,” and the like, herein do not denote any order,quantity, or importance, but rather are used to determine one elementfrom another. The terms “a” and “an” and “the” herein do not denote alimitation of quantity, and are to be construed to cover both thesingular and the plural, unless otherwise indicated herein or clearlycontradicted by context. The suffix “(s)” as used herein is intended toinclude both the singular and the plural of the term that it modifies,thereby including one or more of that term (e.g., the film(s) includesone or more films). Reference throughout the specification to “oneembodiment”, “another embodiment”, “an embodiment”, and so forth, meansthat a particular element (e.g., feature, structure, and/orcharacteristic) described in connection with the embodiment is includedin at least one embodiment described herein, and may or may not bepresent in other embodiments. In addition, it is to be understood thatthe described elements may be combined in any suitable manner in thevarious embodiments.

All cited patents, patent applications, and other references areincorporated herein by reference in their entirety. However, if a termin the present application contradicts or conflicts with a term in theincorporated reference, the term from the present application takesprecedence over the conflicting term from the incorporated reference.

While particular embodiments have been described, alternatives,modifications, variations, improvements, and substantial equivalentsthat are or may be presently unforeseen may arise to applicants orothers skilled in the art. Accordingly, the appended claims as filed andas they may be amended are intended to embrace all such alternatives,modifications variations, improvements, and substantial equivalents.

I/We claim:
 1. A photovoltaic module assembly, comprising: a firstlayer; a polymeric back layer, wherein the back layer comprises apolymeric second layer, a polymeric third layer, and a polymeric supportlayer located between the second layer and the third layer; and aphotovoltaic layer comprising photovoltaic cells, wherein thephotovoltaic layer is located between the first layer and the backlayer; wherein the support layer comprises stiffening elements thatdefine openings that extend in a y direction that is perpendicular to alength of the first layer.
 2. The photovoltaic module assembly of claim1, wherein the stiffening element comprises a vertical stiffeningelement, a horizontal stiffening element, a diagonal stiffening element,or a combination comprising one or more of the foregoing.
 3. Thephotovoltaic module assembly of claim 1, wherein the stiffening elementcomprises a honeycomb array, a triangular array, an R6 array, a hexakisarray, or a combination comprising one or more of the foregoing.
 4. Thephotovoltaic module assembly of claim 1, wherein the support layercomprises openings, wherein the openings are filled.
 5. The photovoltaicmodule assembly of claim 1, wherein the support layer has a thickness of1 to 35 mm, and wherein a thickness of the first layer, the secondlayer, and the third layer is each independently 0.5 to 25 mm.
 6. Thephotovoltaic module assembly of claim 1, wherein the photovoltaic modulehas an increased stiffness and/or an increased flexural strength ascompared to a photovoltaic module that does not comprise the supportlayer.
 7. The photovoltaic module assembly of claim 1, wherein the firstlayer, the second layer, and the third layer each independently comprisea thermoplastic material.
 8. The photovoltaic module assembly of claim1, wherein the first layer comprises poly(methyl methacrylate),polycarbonate, or a combination comprising one or both of the foregoing.9. The photovoltaic module assembly of claim 1, wherein the first layercomprises poly(methyl methacrylate) and is free from a coating.
 10. Thephotovoltaic module assembly of claim 1, wherein the second layer and/orthe third layer comprise an acrylonitrile-styrene-acrylonitrilecopolymer, a polycarbonate-acrylonitrile-styrene-acrylonitrilecopolymer, poly(phenylene oxide), polypropylene, or a combinationcomprising one or more of the foregoing.
 11. The photovoltaic moduleassembly of claim 1, wherein the first layer comprises poly(methylmethacrylate) and the second layer and/or the third layer comprise anacrylonitrile-styrene-acrylonitrile copolymer.
 12. A photovoltaic moduleassembly, comprising: a first layer; a polymeric back layer, wherein theback layer comprises a polymeric second layer, a polymeric third layer,and a polymeric support layer located between the second layer and thethird layer, wherein the support layer comprises stiffening elementsthat define openings that extend in a y direction that is perpendicularto a length of the first layer; a photovoltaic layer comprisingphotovoltaic cells, wherein the photovoltaic layer is located betweenthe first layer and the back layer; and a connector that connects thefirst layer to the second layer; wherein the connector comprises anacrylic foam tape or an acetate foam tape and/or is laser welded to thesecond layer; wherein the connector has at least one of an adhesivestrength of greater than or equal to 0.1 MPa as determined in accordancewith ISO 4587-1979 or an elongation at break of greater than or equal to50% measured in accordance with ISO 4587-1979.
 13. The photovoltaicmodule assembly of claim 1, wherein the first layer has one or both of ahaze level of 0% to 6% when measured at a thickness of 5.0 mm or atransparency of greater than or equal to 80 as measured in accordancewith ASTM D1003-00, Procedure A or Procedure B, using lamp D65.
 14. Thephotovoltaic module assembly of claim 1, wherein the second layer and/orthe third layer is opaque.
 15. The photovoltaic module assembly of claim1, wherein the second layer is white.
 16. The photovoltaic moduleassembly of claim 1, wherein the third layer is black.
 17. Thephotovoltaic module assembly of claim 1, wherein the photovoltaic layerfurther comprises a cured composition.
 18. The photovoltaic moduleassembly of claim 1, wherein the photovoltaic layer has a thickness of0.5 to 10 mm.
 19. The photovoltaic module assembly of claim 1, whereinthe photovoltaic assembly meets at least one of the requirements as setforth in Paragraph 10.11 of IEC 61215 Edition 2, 2005, the requirementsas set forth in Paragraph 10.12 of IEC 61215 Edition 2, 2005, or therequirements as set forth in Paragraph 10.13 of IEC 61215 Edition 2,2005.
 20. A photovoltaic module assembly, comprising: a first layer; apolymeric back layer, wherein the back layer comprises a polymericsecond layer, a polymeric third layer, and a polymeric support layerlocated between the second layer and the third layer; and a photovoltaiclayer comprising photovoltaic cells, wherein the photovoltaic layer islocated between the first layer and the back layer; wherein the supportlayer comprises stiffening elements that define openings that extend ina y direction that is perpendicular to a length of the first layer; andwherein a surface of the third layer opposite the second layer comprisestexturing, fins, ribs, baffles, or a combination comprising at least oneof the foregoing and wherein a surface of the first layer opposite thesecond layer comprises texturing.